Get AUTOMATIC TRANSAXLE (U240E) Guide for Toyota Avensis 4 Door First Generation (1997-2003)

AUTOMATIC TRANSAXLE (U240E)

AUTOMATIC TRANSAXLE SYSTEM . . . . . . .

SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . .

ATF TEMPERATURE SENSOR . . . . . . . . . . . .

NEUTRAL START SWITCH . . . . . . . . . . . . . . .

VALVE BODY ASSEMBLY . . . . . . . . . . . . . . . .

AX–1

AX–3

AX–4

AX–6

AX–8

DIFFERENTIAL OIL SEAL . . . . . . . . . . . . . . . . AX–12

SHIFT LOCK SYSTEM . . . . . . . . . . . . . . . . . . . AX–13

FLOOR SHIFT ASSEMBLY (LHD) . . . . . . . . . . AX–16

FLOOR SHIFT ASSEMBLY (RHD) . . . . . . . . . AX–25

AUTOMATIC TRANSAXLE UNIT . . . . . . . . . . . AX–33

TORQUE CONVERTER AND

DRIVE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . AX–38

AX–1

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLESYSTEM

AUTOMATIC TRANSAXLE SYSTEM

AX0LF–01

PRECAUTION

If the vehicle is equipped with a mobile communication system, refer to the precautions in the IN section.

AVENSIS/CORONA SUP (RM781E)

AX–2

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLESYSTEM

AX0LG–03

OPERATION

1st & Reverse Brake (B )

2

Forward Clutch (C )

1

2nd Brake (B )

1

Direct Clutch (C )

2

No.1 One–way Clutch (F )

1

U/D Brake (B )

3

U/D One–way

Clutch (F )

2

U/D Clutch (C )

3

D05891

f ... Operating

Shift lever range

Gear range

Parking

Reverse

Neutral

1st

C

B

F

1

2

3

1

2

3

1

2

P

R

N

f

2nd

f

D

3rd

f

O/D

f

1st

f

2

L

2nd

f

1st

AVENSIS/CORONA SUP (RM781E)

AX–3

AUTOMATIC TRANSAXLE (U240E)

–

SPEED SENSOR

AX0LI–03

ON–VEHICLE REPAIR

1.

REMOVE AIR CLEANER ASSEMBLY

2.

3.

DISCONNECT COUNTER GEAR SPEED SENSOR

CONNECTOR

REMOVE COUNTER GEAR SENSOR

(a) Remove the bolt and counter gear speed sensor.

D05876

Q04733

D05887

Q04733

(b) Remove the O–ring from the counter gear speed sensor.

4.

INSTALL COUNTER GEAR SPEED SENSOR

O–ring

(a) Coat a new O–ring with ATF and install it to the counter

gear speed sensor.

(b) Install the counter gear speed sensor with the bolt.

Torque: 11.3 N·m (115 kgf·cm, 8 ft·lbf)

5.

CONNECT COUNTER GEAR SPEED SENSOR CON-

NECTOR

6.

7.

DISCONNECT INPUT TURBINE SPEED SENSOR

CONNECTOR

REMOVE INPUT TURBINE SPEED SPEED SENSOR

(a) Remove the bolt and input turbine speed sensor.

(b) Remove the O–ring from the input turbine speed sensor.

8.

INSTALL INPUT TURBINE SPEED SENSOR

O–ring

(a) Coat a new O–ring with ATF and install it to the input tur-

bine speed sensor.

(b) Install the input turbine speed sensor with the bolt.

Torque: 11.3 N·m (115 kgf·cm, 8 ft·lbf)

9.

CONNECT INPUT TURBINE SPEED SENSOR CON-

NECTOR

10. INSTALL AIR CLEANER ASSEMBLY

AVENSIS/CORONA SUP (RM781E)

AX–4

AUTOMATIC TRANSAXLE (U240E)

–

ATF TEMPERATURE SENSOR

AX0LJ–03

ON–VEHICLE REPAIR

1.

2.

DISCONNECT SOLENOID CONNECTOR

REMOVE LH ENGINE UNDER COVER

D05886

D07261

D05879

D02934

3.

4.

REMOVE DRAIN PLUG AND DRAIN ATF

REMOVE OIL PAN AND GASKET

NOTICE:

Some fluid will remain in the oil pan.

Remove the 18 bolts, and carefully remove the oil pan assem-

bly. Discard the gasket.

5.

REMOVE OIL STRAINER

(a) Remove the 3 bolts and oil strainer.

(b) Remove the O–ring.

6.

7.

DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC-

TORS

REMOVE ATF TEMPERATURE SENSOR

Remove the bolt and lock plate, and remove the ATF tempera-

ture sensor.

8.

9.

10. INSTALL ATF TEMPERATURE SENSOR

Install the ATF temperature sensor with the lock plate and bolt.

Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)

SEPARATE WIRE HARNESS FROM 2 CLAMPS

CLAMP WIRE HARNESS TO 2 CLAMPS

11. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS

AVENSIS/CORONA SUP (RM781E)

AX–5

AUTOMATIC TRANSAXLE (U240E)

–

ATF TEMPERATURE SENSOR

12. INSTALL OIL STRAINER

(a) Coat a new O–ring with ATF.

(b) Install the O–ring to the oil strainer.

D05880

D05879

D07261

D05886

(c) Install the oil strainer with the 3 bolts.

Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

13. INSTALL OIL PAN

Install the oil pan and a new gasket with the 18 bolts.

Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

14. INSTALL DRAIN PLUG

Install a new gasket and drain plug.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

15. CONNECT SOLENOID CONNECTOR

16. FILL ATF AND CHECK ATF LEVEL (See page DI–62)

17. INSTALL LH ENGINE UNDER COVER

AVENSIS/CORONA SUP (RM781E)

AX–6

AUTOMATIC TRANSAXLE (U240E)

–

NEUTRAL START SWITCH

AX0LK–03

ON–VEHICLE REPAIR

1.

REMOVE AIR CLEANER ASSEMBLY

2.

DISCONNECT NEUTRAL START SWITCH CONNEC-

TOR

D05911

D05912

D05913

D05914

3.

REMOVE NEUTRAL START SWITCH

(a) Remove the nut.

(b) Remove the nut, washer and control shift lever.

(c) Using a screwdriver, pry off the lock plate.

(d) Remove the nut and lock plate.

AVENSIS/CORONA SUP (RM781E)

AX–7

AUTOMATIC TRANSAXLE (U240E)

–

NEUTRAL START SWITCH

(e) Remove the 2 bolts and pull out the neutral start switch.

4. INSTALL AND ADJUST NEUTRAL START SWITCH

(a) Install the neutral start switch with the 2 bolts.

Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)

(b) Install a new lock plate and nut.

Torque: 6.9 N·m (70 kgf·cm, 61 in.·lbf)

(c) Bend the claws on the lock plate to fix the nut.

D05915

D05913

D05912

D05911

(d) Install the control shift lever with the nut.

Torque: 13 N·m (130 kgf·cm, 9 ft·lbf)

(e) Connect the control cable to the control shaft.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

5.

CONNECT NEUTRAL START SWITCH CONNECTOR

6.

CHECK NEUTRAL START OPERATION

Check that the engine can be started with the shift lever only in

the N or P range, but not in other position.

If the engine can not be stated not as started above, carry out

the adjustment procedure (See page DI–62).

7.

8.

INSTALL AIR CLEANER ASSEMBLY

TEST DRIVE VEHICLE

AVENSIS/CORONA SUP (RM781E)

AX–8

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

AX0LM–03

ON–VEHICLE REPAIR

1.

REMOVE LH ENGINE UNDER COVER

2.

3.

REMOVE DRAIN PLUG AND DRAIN ATF

REMOVE OIL PAN AND GASKET

NOTICE:

Some fluid will remain in the oil pan.

Remove the 18 bolts, and carefully remove the oil pan assem-

bly. Discard the gasket.

D07261

AT0103

D05879

D02934

4.

EXAMINE PARTICLES IN OIL PAN

Remove the magnets and use them to collect any steel chips.

Look carefully at the chips and particles in the pan and on the

magnet to anticipate what type of wear you will find in the trans-

axle.

Steel (magnetic)...bearing, gear and plate wear

Brass (non–magnetic)... bushing wear

5.

REMOVE OIL STRAINER

(a) Remove the 3 bolts and oil strainer.

(b) Remove the O–ring.

6.

7.

DISCONNECT 5 SHIFT SOLENOID VALVE CONNEC-

TORS

REMOVE ATF TEMPERATURE SENSOR

Remove the bolt and lock plate, and remove the ATF tempera-

ture sensor.

8.

SEPARATE WIRE HARNESS FROM 2 CLAMPS

AVENSIS/CORONA SUP (RM781E)

AX–9

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

9.

REMOVE VALVE BODY

Remove the 17 bolts and valve body.

NOTICE:

Be careful not to drop the check valve body, spring and ac-

cumulator piston.

D02935

D02936

D02937

D02938

D02937

10. REMOVE CHECK BALL BODY AND SPRING

11. REMOVE 2 APPLY GASKETS

12. REMOVE SHIFT SOLENOID VALVE

Remove the 5 bolts and 5 shift solenoid valves.

13. INSTALL SHIFT SOLENOID VALVE

Install the 5 shift solenoid valves with the 5 bolts.

Torque:

B

A

B

A

Bolt A: 6.6 N·m (67 kgf·cm, 58 in.·lbf)

Bolt B: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

Bolt length:

Bolt A: 12 mm (0.47 in.)

Bolt B: 45 mm (1.77 in.)

14. INSTALL 2 APPLY GASKETS

(a) Coat 2 new apply gaskets with ATF.

(b) Install the 2 gaskets to the transaxle case.

AVENSIS/CORONA SUP (RM781E)

AX–10

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

15. INSTALL CHECK VALVE AND SPRING

D02936

16. INSTALL VALVE BODY

A

(a) Align the groove of the manual valve with the pin of the

manual valve lever.

(b) Temporarily install the valve body with the 17 bolts.

Bolt length:

C

A

C

Bolt A: 25 mm (0.98 in.)

Bolt B: 41 mm (1.61 in.)

Bolt C: 45 mm (1.77 in.)

B

C

(c) Check that the manual valve lever contacts the center of

the roller at the tip of the detent spring.

(d) Tighten the 17 bolts.

D02935

B

Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

17. CLAMP WIRE HARNESS TO 2 CLAMPS

18. INSTALL ATF TEMPERATURE SENSOR

Install the ATF temperature sensor with the lock plate and bolt.

Torque: 6.6 N·m (67 kgf·cm, 58 in.·lbf)

19. CONNECT 5 SHIFT SOLENOID VALVE CONNECTORS

D02934

20. INSTALL OIL STRAINER

(a) Coat a new O–ring with ATF.

(b) Install the O–ring to the oil strainer.

D05880

AVENSIS/CORONA SUP (RM781E)

AX–11

AUTOMATIC TRANSAXLE (U240E)

–

VALVE BODY ASSEMBLY

(c) Install the oil strainer with the 3 bolts.

Torque: 10.8 N·m (110 kgf·cm, 8 ft·lbf)

D05879

D02940

D07261

21. INSTALL MAGNET IN OIL PAN

Install the 3 magnets in the oil pan, as shown in the illustration.

22. INSTALL OIL PAN

Install the oil pan and a new gasket with the 18 bolts.

Torque: 7.8 N·m (80 kgf·cm, 69 in.·lbf)

23. INSTALL DRAIN PLUG

Install a new gasket and drain plug.

Torque: 49 N·m (500 kgf·cm, 36 ft·lbf)

24. FILL ATF AND CHECK ATF LEVEL (See page DI–62)

25. INSTALL LH ENGINE UNDER COVER

AVENSIS/CORONA SUP (RM781E)

AX–12

AUTOMATIC TRANSAXLE (U240E)

–

DIFFERENTIALOIL SEAL

DIFFERENTIAL OIL SEAL

AX0LN–02

ON–VEHICLE REPAIR

1.

2.

DRAIN ATF

REMOVE LH AND RH DRIVE SHAFTS (See page

SA–3)

D07261

D03284

D05870

D03286

3.

REMOVE LH AND RH SIDE OIL SEAL

Using SST, drive out both the side oil seals.

SST 09308–10010

SST

4.

INSTALL LH SIDE OIL SEAL

(a) Using SST and a hammer, drive in a new oil seal.

SST 09350–32014 (09351–32130, 09351–32150)

Oil seal drive in depth: 2.7± 0.5 mm (0.106 ± 0.020 in.)

(b) Coat the oil seal lip with MP grease.

SST

5.

INSTALL RH SIDE OIL SEAL

(a) Using SST and a hammer, drive in a new oil seal.

SST 09223–00010

Oil seal drive in depth: 0 ± 0.5 mm (0 ± 0.020 in.)

(b) Coat the oil seal lip with MP grease.

6.

INSTALL LH AND RH DRIVE SHAFTS (See page

SA–12)

FILL ATF AND CHECK ATF LEVEL (See page DI–62)

SST

7.

AVENSIS/CORONA SUP (RM781E)

AX–13

AUTOMATIC TRANSAXLE (U240E)

–

SHIFTLOCK SYSTEM

SHIFT LOCK SYSTEM

AX10Y–01

LOCATION

KeyInterlockSolenoid

Stop Light Switch

Shift Lock Control Computer

D10026

AVENSIS/CORONA SUP (RM781E)

AX–14

AUTOMATIC TRANSAXLE (U240E)

–

SHIFTLOCK SYSTEM

AX10Z–01

INSPECTION

5 (IG)

1 (ACC)

1.

LHD:

4 (KLS+)

INSPECT SHIFT LOCK CONTROL COMPUTER

Using a voltmeter, measure the voltage at each terminal.

HINT:

3 (E)

Do not disconnect the shift lock control computer connector.

2 (STP)

Wire harness side

D00758

Terminal

MeasuringCondition

Voltage (V)

10 – 14

1 – 3 (ACC – E)

5 – 3 (IG – E)

Ignition switch ACC

Ignition switch ON

10 – 14

2 – 3 (STP – E)

Depressing brake pedal

10 – 14

(1) Ignition switch ACC and P range

0

+

4 – 3 (KLS – E)

(2) Ignition switch ACC and except P range

7.5 – 11

6 – 9.5

(3) Ignition switch ACC and except P range (After approx. 1 second)

2.

RHD:

INSPECT SHIFT LOCK CONTROL COMPUTER

Using a voltmeter, measure the voltage at each terminal.

HINT:

Do not disconnect the shift control computer connector.

D05910

Terminal

MeasuringCondition

Voltage (V)

10 – 14

2 – 3 (ACC – E)

4 – 3 (IG – E)

5 – 3 (STP – E)

Ignition switch ACC

Ignition switch ON

10 – 14

Depressing brake pedal

10 – 14

(1) Ignition switch ACC and P range

0

+

1 – 3 (KLS – E)

(2) Ignition switch ACC and except P range

7.5 – 11

6 – 9.5

(3) Ignition switch ACC and except P range (After approx. 1 second)

AVENSIS/CORONA SUP (RM781E)

AX–15

AUTOMATIC TRANSAXLE (U240E)

–

SHIFTLOCK SYSTEM

3.

INSPECT KEY INTERLOCK SOLENOID

(a) Disconnect the solenoid connector.

(b) Using an ohmmeter, measure the resistance between the

terminals.

–

+

KLS

Standard resistance: 12.5 – 16.5 Ω

If the resistance value is not as specified, replace the solenoid.

D08869

(c) Provide the battery voltage between the terminals.

Check that the solenoid can be heard its operating.

If the operation is not as specified, replace the solenoid.

–

+

KLS

D08870

AVENSIS/CORONA SUP (RM781E)

AX–16

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX02U–08

COMPONENTS

Parking Brake Cover

12 (120, 9)

Clip

Shift Control Cable

Shift Lever Assembly

Cap

Rear Console Box

: Specified torque

N·m (kgf·cm, ft·lbf)

D10190

AVENSIS/CORONA SUP (RM781E)

AX–17

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

Pattern Select Switch

Position Indicator

Upper Housing

Shift Lever Knob Sub–assembly

Spring

Shift Lever Knob

Sleeve

Shift Lever Button

Detent Rod

Position Indicator

Slide Cover

O/D Main Switch

L

Position

Indicator Plate

Spring

Position Indicator

Lower Housing

Shift Lever Knob Cover

Cap

Bulb

Grooved Pin

Spring Plate

Indicator Light

Wire

Shift Lever Sub–assembly

Shift Lever Plate

Shift Lock Release Button

Spring

Shift Lock

Control Computer

Control Shaft

Collar

MP grease

L Precoated part

D09906

AVENSIS/CORONA SUP (RM781E)

AX–18

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX05L–03

REMOVAL

1.

2.

REMOVE REAR CONSOLE (See page BO–8)

REMOVE SHIFT LEVER ASSEMBLY

(a) Disconnect the 3 connectors and wire harness.

(b) Remove the clip and disconnect the shift control cable.

(c) Remove the 4 bolts and floor shift assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02081

AVENSIS/CORONA SUP (RM781E)

AX–19

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX0C5–04

DISASSEMBLY

1.

REMOVE O/D MAIN SWITCH TERMINAL

(a) Remove the O/D main switch connector from the shift le-

ver plate.

3

(b) Disengage the secondary locking device.

(c) Release the locking lug of the terminals 2 and 4, and pull

the terminals out from the rear.

2

1

Secondary Locking Device

A00451

2.

REMOVE SHIFT LEVER KNOB SUB–ASSEMBLY

(a) Remove the 2 screws and shift lever knob sub–assembly.

NOTICE:

Pay attention not to put unnatural load onto O/D main

switch wire harness.

(b) Remove the shift lever knob cover.

(c) Remove the shift lever button and spring.

(d) Remove the O/D main switch.

3.

4.

REMOVE INDICATOR LIGHT WIRE

REMOVE CAP AND BULB FROM INDICATOR LIGHT

WIRE

5.

REMOVE INDICATOR HOUSING

Remove the screws and an indicator housing.

6.

DISASSEMBLE INDICATOR HOUSING

(a) Remove the pattern select switch.

(b) Remove the position indicator lower housing.

(c) Remove the shift lock release button and spring.

(d) Remove the position indicator slide cover.

(e) Remove the position indicator plate.

D08694

7.

Remove the 2 screws and shift lock control computer.

8. REMOVE SPRING PLATE

REMOVE SHIFT LOCK CONTROL COMPUTER

AVENSIS/CORONA SUP (RM781E)

AX–20

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

9.

REMOVE SHIFT LEVER SUB–ASSEMBLY

(a) Using a screwdriver and a hammer, remove the control

shaft.

(b) Remove the shift lever sub–assembly.

F00683

D04313

F00687

F00685

10. DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY

(a) Measure the distance ”A” between the lower edge of the

shift lever knob sleeve and the upper edge of the shift le-

ver sub–assembly.

A

(b) Using a hammer, remove the grooved pin.

NOTICE:

When pressing down the grooved pin, if doing it at the

place other than the notch, there may be fear of damaging

the shift lever sub–assembly.

(c) Remove the detent rod and spring.

(d) Remove the shift lever knob sleeve from the detent rod.

11. REMOVE COLLARS

Using a screwdriver and a hammer, remove the 4 collars.

AVENSIS/CORONA SUP (RM781E)

AX–21

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX0C6–04

REASSEMBLY

1.

2.

INSTALL COLLARS

INSTALL SHIFT LEVER KNOB SLEEVE TO DETENT

ROD

3.

ASSEMBLE SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply MP grease on the compression spring, the detent

rod and the shift lever sub–assembly.

(b) Install the spring and the detent rod to shift lever sub–as-

sembly.

F00686

F00684

F00688

F00689

(c) Place the shift lever sub–assembly as shown in the il-

lustration.

(d) Insert the grooved pin in the detent rod pin hole.

NOTICE:

Correct

Wrong

S

Assemble the grooved pin to ensure that it fits into the

guide hole of the shift lever sub–assembly in parallel.

Take care not to insert the pin in the wrong direction

of the detent rod.

S

(e) Meet the grooved pin with the notch of the guide hole.

AVENSIS/CORONA SUP (RM781E)

AX–22

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

(f)

Press the pin with a hammer.

A: 10.0 – 10.4 mm (0.39 – 0.41 in.)

Shift Lever

Sub–assembly

A

NOTICE:

When pressing in the grooved pin, if doing it at the place

other than the notch, the shift lever sub–assembly might be

damaged.

Detent Rod

4.

CHECK DETENT ROD OPERATION

Grooved Pin

F01188

D04313

F00690

F00691

F00692

A00452

5.

INSTALL SHIFT LEVER KNOB SLEEVE DETENT ROD

Drive the shift lever knob sleeve to the distance A measured be-

fore removal.

A

6.

INSTALL SHIFT LEVER SUB–ASSEMBLY

(a) Apply MP grease.

: Apply MP Grease

(b) Using a brass bar and a hammer, install the control shaft

and the shift lever sub–assembly to the shift lever plate.

NOTICE:

Take care not to install them in the wrong direction of the

shift lever sub–assembly.

7.

INSTALL SPRING PLATE

8.

INSTALL SHIFT LOCK CONTROL COMPUTER

Install the shift control control computer and 2 screws.

NOTICE:

Install the grooved pin into the groove of the shift lock unit

as shown in the illustration.

AVENSIS/CORONA SUP (RM781E)

AX–23

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

9.

ASSEMBLE INDICATOR HOUSING

(a) Install the position indicator plate.

(b) Install the position indicator slide cover.

(c) Install the spring and shift lock release button.

(d) Install the position indicator lower housing.

(e) Install the pattern select switch.

NOTICE:

Do not make indicator housing dirty with MP grease.

10. INSTALL INDICATOR HOUSING

Install the screws and an indicator housing.

11. INSTALL CAP AND BULB TO INDICATOR LIGHT WIRE

12. INSTALL INDICATOR LIGHT WIRE

13. INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY

(a) Install the O/D main switch.

(b) Install the spring and shift lever button.

(c) Install the shift lever knob cover.

HINT:

Apply MP grease to shift lever knob button.

(d) Install the shift lever sub–assembly and 2 screws.

HINT:

Coat the threads of the screws with sealant.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

NOTICE:

Make sure not to catch O/D main switch wire harness.

(e) Install the O/D main switch wire harness securely to hung

on the hook of the shift lever sub–assembly.

14. INSTALL O/D MAIN SWITCH TERMINAL

AVENSIS/CORONA SUP (RM781E)

AX–24

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (LHD)

AX02Y–08

INSTALLATION

INSTALL FLOOR SHIFT ASSEMBLY

Installation is in the reverse order of removal (See page

AX–18).

HINT:

After installation, adjust shift lever ranges (See page DI–62)

and inspect shift lever operation.

S

When shifting it to each range, make sure that the shifting

lever moves smoothly, can be moderately operated and

the range indicator displays correctly.

Ranges which can be operated without pressing the

shift lever nob button

R → N → D→ 2

With the brake pedal depressed,

shift while holding the lock

release button in. (The ignition

switch must be in ON position.)

Ranges which can be operated only with pressing the

shift lever nob button

P → R, 2 → L, N → R → P

When starting the engine, make sure that the vehicle

moves forward when shifting from N to D range, and

moves rearward when shifting to R range.

Shift while holding the lock

release button in.

S

Shift normally

D02013

AVENSIS/CORONA SUP (RM781E)

AX–25

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX05N–02

COMPONENTS

12 (120, 9)

Clip

Rear Console Box

Shift Control Cable

Shift Lever

Assembly

Cap

Parking Brake Cover

N·m (kgf·cm, ft·lbf) : Specified torque

D02091

AVENSIS/CORONA SUP (RM781E)

AX–26

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

Shift Lever Button

Spring

Pattern Select Switch

Shift Lever Knob

Position Indicator Plate

Position Indicator

Upper Housing

L

O/D Main

Switch

Position Indicator

Slide Cover

Detent Rod

Bulb

Shift Lever Knob

Cover

Indicator Light Wire

Spring

Stopper Pin

Control Shaft

Detent Roller

Holder

Spring

Shift Lever Sub–Assembly

Shift Lock Control Computer

Shift Lock Plate

Shift Lock Release Button

Spring

Shift Lever

Plate

x 4

Collar

MP grease

L Precoated part

D09907

AVENSIS/CORONA SUP (RM781E)

AX–27

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX05O–02

REMOVAL

1.

2.

REMOVE REAR CONSOLE (See page BO–8)

REMOVE FLOOR SHIFT ASSEMBLY

(a) Disconnect the connectors.

(b) Remove the clip and disconnect the shift control cable.

(c) Remove the 4 bolts and shift lever assembly.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

D02093

AVENSIS/CORONA SUP (RM781E)

AX–28

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX110–01

DISASSEMBLY

1.

REMOVE O/D MAIN SWITCH TERMINAL

(a) Remove O/D main switch connector from the shift lever

plate.

3

(b) Disengage the secondary locking device.

(c) Disengage the locking lug of the terminals 2 and 4, and

pull the terminals out from the rear.

2

1

2.

REMOVE SHIFT LEVER KNOB SUB–ASSEMBLY

Secondary Locking Device

A00451

(a) Remove the 2 screws and shift lever knob sub–assembly.

NOTICE:

Pay attention not to apply unnatural load onto O/D main

switch wire harness.

(b) Remove the Shift lever knob cover.

(c) Remove the Shift lever button and spring.

(d) Remove the O/D main switch.

3.

4.

5.

REMOVE INDICATOR LIGHT WIRE

REMOVE BULB FROM INDICATOR LIGHT WIRE

REMOVE INDICATOR HOUSING SUB–ASSEMBLY

6.

DISASSEMBLE INDICATOR HOUSING SUB–AS-

SEMBLY

(a) Remove the position indicator side cover.

(b) Remove the position indicator plate.

(c) Remove the pattern select switch.

D02094

7.

REMOVE SHIFT LOCK CONTROL COMPUTER

Remove the 3 screws and shift lock control computer.

D09908

8.

REMOVE STOPPER PIN, DETENT ROD AND SPRING

AVENSIS/CORONA SUP (RM781E)

AX–29

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

9.

REMOVE SHIFT LEVER SUB–ASSEMBLY

(a) Using an extension bar and hammer, remove the control

shaft.

(b) Remove the shift lever sub–assembly.

D02095

D02096

D02040

10. DISASSEMBLE SHIFT LEVER SUB–ASSEMBLY

(a) Remove the Detent roller holder.

(b) Remove the Compression spring.

11. REMOVE COLLARS

Using an extension bar and hammer, remove the 4 collars.

AVENSIS/CORONA SUP (RM781E)

AX–30

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX05Q–02

REASSEMBLY

1.

INSTALL COLLARS

2.

ASSEMBLE SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply the MP grease to the detent roller holder, compres-

sion spring and shift lever sub–assembly.

(b) Install the compression spring to the detent roller holder.

(c) Install the detent roller holder with the compression spring

to the shift lever sub–assembly.

D02096

3.

INSTALL SHIFT LEVER SUB–ASSEMBLY

: Apply MP Grease

(a) Apply the MP grease to the control shaft and shift lever

sub–assembly.

(b) Using an extension bar and hammer, install the control

shaft and shift lever sub–assembly to the shift lever plate.

4.

INSTALL SPRING, DETENT ROD AND STOPPER PIN

(a) Apply the MP grease to the detent rod and stopper pin.

(b) Install the compression spring and detent rod to the shift

lever sub–assembly.

D02041

(c) Insert the stopper pin in the stopper pin hole.

NOTICE:

Take care not to insert the pin in the wrong direction

against the detent rod.

5.

INSTALL SHIFT LOCK CONTROL COMPUTER

Install the shift lock control computer with 3 screws.

6.

7.

CHECK SHIFT LEVER OPERATION

ASSEMBLE INDICATOR HOUSING SUB–ASSEMBLY

(a) Install the pattern select switch.

(b) Install the position indicator plate.

(c) Install the position indicator slide plate.

8.

9.

INSTALL INDICATOR HOUSING SUB–ASSEMBLY

INSTALL BULB TO INDICATOR LIGHT WIRE

10. INSTALL INDICATOR LIGHT WIRE

AVENSIS/CORONA SUP (RM781E)

AX–31

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

11. INSTALL SHIFT LEVER KNOB SUB–ASSEMBLY

HINT:

Apply MP grease to the shift lever knob button.

(a) Install the O/D main switch.

(b) Install the shift lever button and spring.

(c) Install the shift lever knob cover.

(d) Install the shift lever knob sub–assembly and 2 screws.

HINT:

Coat the threads of the screws with sealant.

Sealant:

Part No. 08833–00080, THREE BOND 1344, LOCTITE

242 or equivalent

NOTICE:

Make sure not to catch O/D main switch wire harness.

(e) Install the O/D main switch wire harness securely and

hang it on the hook of the shift lever sub–assembly.

12. INSTALL O/D MAIN SWITCH TERMINAL

AVENSIS/CORONA SUP (RM781E)

AX–32

AUTOMATIC TRANSAXLE (U240E)

–

FLOOR SHIFT ASSEMBLY (RHD)

AX05R–03

INSTALLATION

INSTALL FLOOR SHIFT ASSEMBLY

Installation is in the reverse order of removal (See page

AX–27).

HINT:

After installation, adjust shift lever ranges (See page DI–62)

and inspect shift lever operation.

S

When shifting it to each range, make sure that the shifting

lever moves smoothly, can be moderately operated and

the range indicator displays correctly.

Ranges which can be operated without pressing the

shift lever nob button

R → N → D→ 2

With the brake pedal depressed,

shift while holding the lock

release button in. (The ignition

switch must be in ON position.)

Ranges which can be operated only with pressing the

shift lever nob button

P → R, 2 → L, N → R → P

When starting the engine, make sure that the vehicle

moves forward when shifting from N to D range, and

moves rearward when shifting to R range.

Shift while holding the lock

release button in.

S

Shift normally

D02013

AVENSIS/CORONA SUP (RM781E)

AX–33

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX064–02

COMPONENTS

Battery

Air Cleaner Assembly

RH Drive Shaft

87 (890, 64)

64 (650, 47)

Torque Converter Clutch

18 (185, 13)

41 (420, 30)

Ground Cable

46 (470, 34)

x 6

52 (530, 38)

87 (890, 64)

Hole Plug

64 (650, 47)

z Snap Ring

LH Drive Shaft

225 (2,305, 167)

Control Cable

z Cotter Pin

Starter

Clip

Plug for Hydraulic Test

39 (400, 29)

10 (100, 7)

Lock Nut Cap

12 (120, 9)

39 (400, 29)

Exhaust Front Pipe

127 (1,300, 94)

Engine Under Cover RH

43 (440, 32)

Suction Hose (RHD)

Front Center Member

73 (740, 54)

Grommet

Engine Under Cover LH

x 5

62 (630, 46)

72 (740, 53)

z

Grommet

73 (740, 54)

Front Center Member

Protector

x 5

N·m (kgf·cm, ft·lbf) : Specified torque

39 (400, 29)

D09909

z Non–reusable part

AVENSIS/CORONA SUP (RM781E)

AX–34

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX111–01

REMOVAL

1.

2.

REMOVE BATTERY

REMOVE AIR CLEANER ASSEMBLY

3.

REMOVE STARTER

(a) Remove the nut and disconnect the connector.

(b) Remove the 2 bolts, bracket and starter.

Torque: 39 N·m (400 kgf·cm, 29 ft·lbf)

4.

DISCONNECT GROUND CABLE

Torque: 18 N·m (185 kgf·cm, 13 ft·lbf)

D09912

D09913

D02517

D02518

5.

REMOVE 4 UPPER SIDE TRANSAXLE MOUNTING

BOLTS

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

6.

7.

INSTALL ENGINE SUPPORT FIXTURE

REMOVE ENGINE UNDER COVERS

8.

REMOVE LH SIDE ENGINE MOUNTING

A

Remove the 5 bolts, nut and LH engine mounting.

Torque:

A

A: 52 N·m (530 kgf·cm, 38 ft·lbf)

B: 87 N·m (890 kgf·cm, 64 ft·lbf)

REMOVE LH AND RH DRIVE SHAFTS (See page

SA–3)

9.

B

A

AVENSIS/CORONA SUP (RM781E)

AX–35

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

10. DISCONNECT SHIFT CONTROL CABLE

Remove the nut, clip and disconnect the shift control cable.

Torque: 12 N·m (120 kgf·cm, 9 ft·lbf)

11. DISCONNECT NEUTRAL START SWITCH CONNEC-

TOR AND SOLENOID CONNECTOR

12. DISCONNECT VEHICLE SPEED SENSOR CONNEC-

TOR

D09914

13. REMOVE EXHAUST FRONT PIPE

(a) Disconnect the oxygen sensor connector.

(b) Remove the 2 nuts from the exhaust manifold.

Torque: 62 N·m (630 kgf·cm, 46 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

Replace the used nuts with new ones.

(c) Remove the 2 bolts, nuts and exhaust front pipe with 2

gaskets.

D09915

Torque: 43 N·m (440 kgf·cm, 32 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

Replace the used nuts with new ones.

(d) Remove the 2 gaskets from the exhaust front pipe.

HINT:

At the time of installation, please refer to the following item.

Replace the used gaskets with new ones.

14. REMOVE FRONT CENTER MEMBER

(a) RHD:

A

C

Remove the nut and disconnect the suction hose from the

front center member.

(b) Remove the 9 bolts, 3 grommets, front center member

protector and front center member.

Torque:

A

A: 73 N·m (740 kgf·cm, 54 ft·lbf)

B: 39 N·m (400 kgf·cm, 29 ft·lbf)

C: 72 N·m (740 kgf·cm, 53 ft·lbf)

15. DISCONNECT OIL COOLER HOSES

B

D02064

D02523

AVENSIS/CORONA SUP (RM781E)

AX–36

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

16. SUPPORT TRANSAXLE

D02524

D10022

D02044

D10023

17. REMOVE ENGINE REAR MOUNTING BOLT

Torque: 87 N·m (890 kgf·cm, 64 ft·lbf)

18. REMOVE ENGINE REAR MOUNTING BRACKET

Remove the 3 bolts and engine rear mounting bracket.

Torque: 64 N·m (650 kgf·cm, 47 ft·lbf)

19. REMOVE TRANSAXLE

(a) Turn the crankshaft to gain access and remove the 6 bolts

with holding the crankshaft pulley bolt by a wrench.

Torque: 41 N·m (420 kgf·cm, 30 ft·lbf)

HINT:

At the time of installation, please refer to the following item.

First, install the gray bolt. Then install 5 black bolts.

(b) Remove the 4 bolts.

Torque: 46 N·m (470 kgf·cm, 34 ft·lbf)

(c) Lower the left side of the engine and remove the transaxle

from the engine.

HINT:

At the time of installation, please refer to the following item.

Temporarily tighten the transaxle mounting bolts.

AVENSIS/CORONA SUP (RM781E)

AX–37

AUTOMATIC TRANSAXLE (U240E)

–

AUTOMATIC TRANSAXLE UNIT

AX066–02

INSTALLATION

1.

CHECK TORQUE CONVERTER INSTALLATION

Using a scale and a straight edge, measure the distance from

the installation surface to the front surface of the transaxle

housing.

Correct distance: More than 12.75 mm (0.502 in.)

2.

TRANSAXLE INSTALLATION

Installation is in the reverse order of removal (See page

AX–34).

D02529

HINT:

S

After installation, adjust the shift control cable and neutral

start switch (See page DI–62).

S

Fill ATF and check fluid level (See page DI–62).

Perform the test drive of the vehicle (See page DI–62).

AVENSIS/CORONA SUP (RM781E)

AX–38

AUTOMATIC TRANSAXLE (U240E)

–

TORQUE CONVERTER AND DRIVE PLATE

SST

TORQUE CONVERTER AND DRIVE

PLATE

AX067–02

INSPECTION

1.

INSPECT ONE–WAY CLUTCH

(a) Install SST into the inner race of the one–way clutch.

SST 09350–32014 (09351–32010)

(b) Install SST so that it fits in the notch of the converter hub

and outer race of the one–way clutch.

AT0953

SST 09350–32014 (09351–32020)

(c) With the torque converter set up on its side, check that the

clutch locks when it is turned counterclockwise, and ro-

tates smoothly clockwise.

Hold

If necessary, clean the converter and retest the clutch.

Replace the converter if the clutch still fails the test.

Lock

Free

Turn

AT3306

D02544

D02545

2.

MEASURE DRIVE PLATE RUNOUT AND INSPECT

RING GEAR

(a) Set up a dial indicator and measure the drive plate runout.

(b) Check the damage of the ring gear.

Maximum runout: 0.20 mm (0.0079 in.)

If the runout is not within the specification or ring gear is dam-

aged, replace the drive plate.

Torque: 98 N·m (1,000 kgf·cm 72 ft·lbf)

3.

MEASURE TORQUE CONVERTER SLEEVE RUNOUT

Temporarily mount the torque converter to the drive plate. Set

up a dial indicator and measure the torque converter sleeve

runout.

Maximum runout: 0.30 mm (0.0118 in.)

If the runout is not within the specification, try to correct by reori-

enting the installation of the converter.

HINT:

Mark the position of the converter to ensure the correct installa-

tion.

AVENSIS/CORONA SUP (RM781E)

AUTOMATIC TRANSAXLE (U240E) for Your Toyota Avensis 4 Door First Generation (1997-2003)

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